Flight Simulator & Accessories
Custom flight simulator framework using 1.5-inch aluminum tubing and 3D-printed adapters for ease of assembly. This innovative design creates an affordable, space-efficient enclosed simulator that fits in a 5'x5' space, making high-end simulation accessible for home users.
The Challenge
Traditional enclosed flight simulators are prohibitively expensive ($75k+) and require significant space. After analyzing an initial hardwood prototype, the goal was to create a cost-effective, modular design that could be easily manufactured, shipped, and assembled while maintaining professional-grade stability.
The Solution
Engineered a flight simulator "kit" in Fusion 360 featuring custom-designed 98A TPU joints that securely connect aluminum tubing components. The TPU material choice provides optimal rigidity while preventing stress fractures common in harder plastics. Developed complementary accessories including iPad gauge cluster mounts for live flight data integration. The modular design supports both self-build plans and complete kit options.
Key Results
Created a space-efficient design fitting within a 5'x5' footprint for apartment compatibility
Achieved significant cost reduction compared to commercial alternatives ($75k+)
Developed a modular framework supporting future racing simulation integration
Engineered custom TPU joints that ensure stability while enabling easy assembly
Designed user-friendly accessories enhancing simulation immersion
Project Gallery
Technologies Used
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